Technical Field
[0001] This invention pertains to the field of expelling liquid propellant but not pressurant
gas from a liquid propellant tank on board a spacecraft.
Background Art
[0002] DeBrock et al., "A Survey of Current Developments in Surface Tension Devices for
Propellant Acquisition",
Journal of Spacecraft and Rockets, Vol. 8, No. 2, February 1971, pp. 83-98, shows a number of propellant management
devices for spacecraft liquid propellant tanks. For example, Fig. 4 shows a system
of screened galleries, formed using rectangular channels, extending throughout the
interior of the tank. In the present invention, screens or other relatively closed
portions 10 of liquid communication channels 2 do not extend all the way into the
upper half 3 of the tank 1; and the liquid communication channels 2 are preferably
V-shaped.
[0003] U.S. patent 3,923,188 shows another type of rectangular-cross-section screened gallery
propellant management system (PMS) in which the screens extend all the way into the
upper reaches of the tank. Unlike the present invention, the reference device has
no flat spin recovery capability and no capability for adverse acceleration conditions
when the propellant quantity is small.
[0004] U.S. patent 4,272,257 shows a propellant management system having liquid-vapor separators
inserted into galleries. The separators, which serve the same role as screens, extend
all the way into the upper half of the tank. This presents the same disadvantages
as with those prior art devices using screens, which disadvantages are overcome by
the present invention as will be explained
infra. The reference device does not disclose a flat spin capability as in the present
invention. In col. 1, lines 35-36, the reference patent mentions triangular-shaped
port openings in prior art screened gallery PMS's.
[0005] U.S. patent 4,399,831 shows a propellant management system having rectangular-cross-section
screened galleries extending all the way into the upper half of the tank. Chamber
27 surrounding solid 26 is used for a bubble trap, but this structure does not perform
all of the functions, such as liquid communication, as bubble trap assembly 9 of the
present invention.
[0006] U.S. patent 4,553,565 shows a propellant management system using vane channels (Figs.
5A and 5B). The channels have less propellant retention and acquisition capability
than the V-shaped channels 2 described in the present specification. The reference
device does not have a flat spin recovery capability or a spinup capability as in
the present invention.
Disclosure of Invention
[0007] The present invention is a propellant management system (PMS) for a liquid propellant
tank used on board a spacecraft. The instant PMS can accommodate many different spacecraft
maneuvers. A hollow tank (1) contains a liquid propellant and a pressurant gas ullage.
An outlet port (8) is situated in a half (5) of the tank (1) associated with the outlet
port (8). Several elongated preferably V-cross-section channels (2) communicate liquid
propellant to the outlet port (8) from interior regions of the tank (1), including
those in that half (3) of the tank (1) not associated with the outlet port (8). The
channels (2) are relatively more open in portions of the tank (1) where pressurant
gas ullage is expected to be present, e.g., during high-g spacecraft maneuvers, compared
with regions where liquid propellant is expected to be present. Because of this, during
high g maneuvers, the ullage advantageously does not descend into relatively closed
portions (10) of the channels (2), where it could be trapped.
Brief Description of the Drawings
[0008] These and other more detailed and specific objects and features of the present invention
are more fully disclosed in the following specification, reference being had to the
accompanying drawings, in which:
Figure 1 is an isometric partially broken-away overview of a spacecraft liquid propellant
tank 1 that utilizes the present invention;
Figure 2 is a side sectional view of the tank 1 of Fig. 1;
Figure 3 is a sectional view of a relatively open portion 11 of V-channel 2C from
Fig. 2 viewed along viewlines 3-3;
Figure 4 is a sectional view of a relatively closed portion 10 of V-channel 2C from
Fig. 2 viewed along viewlines 4-4;
Figure 5 is an isometric partially broken-away view of bubble trap assembly 9 of tank
1 of Fig. 1;
Figure 6 is a side sectional view of tank 1 of Fig. 1 showing the distribution of
liquid propellant during a spinup maneuver;
Figure 7 is a side sectional view of two tanks 1A, 1B of the Fig. 1 variety, illustrating
distribution of liquid propellant for a spin about the spacecraft's principal axis,
for the case where tanks 1A, 1B are more than 50% full of propellant;
Figure 8 is a side sectional view of tank 1 of Fig. 1 showing distribution of liquid
propellant following an apogee kick motor firing maneuver;
Figure 9 is a side sectional view of two tanks 1A, 1B of the Fig. 1 variety, illustrating
distribution of liquid propellant for a spin about the spacecraft's principal axis,
for the case where tanks 1A, 1B are less than 50% full of propellant;
Figure 10 is a side sectional view of tank 1 of Fig. 1 showing distribution of propellant
during a north stationkeeping maneuver; and
Figure 11 is a side sectional view of tank 1 of Fig. 1 showing distribution of propellant
during a west stationkeeping maneuver.
Best Mode for Carrying Out the Invention
[0009] Three-axis stabilized spacecraft, including satellites, require propulsion systems
with a propellant management system (PMS) to provide gas-free propellant delivery
on demand for all orbital maneuvers throughout the entire mission. The PMS must also
be designed to provide high expulsion efficiency to minimize the propellant "residuals",
i.e., that propellant which is unavailable for propulsion.
[0010] Active PMS's using bellows, bladders, or diaphragms were formerely in vogue. Passive
PMS's such as the one described herein, which operate on the basis of surface tension,
have replaced active PMS's for many spacecraft applications. Vane and screened gallery
PMS's are the two most commonly used surface tension PMS's. The most serious drawback
of the screened gallery PMS is that pressurant gas is accumulated and retained (trapped)
inside the gallery system. This results in performance degradation and eventual loss
of capillary retention capability. In addition, the screened gallery is expensive
and difficult to fabricate. Vane PMS's, on the other hand, while not exhibiting the
gas entrapment problem, have solely open liquid communication vanes, which severely
limits their liquid propellant retention capability.
[0011] The present invention overcomes these difficulties by providing an improved passive
propellant acquisition and management system. The improved system minimizes the trapped
gas problem, while offering better propellant retention, acquisition, and pumping
capabilities. Propellant residuals are kept to a minimum. Furthermore, the present
invention exhibits an increase in propellant retention capability when operating under
adverse acceleration conditions, and can accommodate flat spin, spinup, lateral acceleration,
and other maneuvers.
[0012] As shown in Fig. 1, the invention resides in a hollow, closed propellant pressure
tank (vessel) 1. Tank 1 may be made of steel or titanium. In the illustrated embodiment,
tank 1 has the form of a sphere comprising upper and lower hemispherical sections
3, 5, respectively; and a diameter of 40". Tank 1 could just as readily have an elongated
cylindrical or some other shape. Tank 1 includes a pressurant inlet 7, a propellant
outlet 8 (which also serves as a propellant inlet for loading), four elongated V-shaped
liquid communication channels 2, and a liquid/bubble trap assembly 9.
[0013] The four V-shaped channels (2A through 2D) are arranged in pairs of opposed channels.
Channels 2A and 2C comprise a first pair, and channels 2B and 2D comprise a second
pair. The plane of the first pair is orthogonal to the plane of the second pair, whereby
each individual channel 2 is mutually orthogonal to its two adjacent channels 2. The
channels 2 are curved to conform generally to the curvature of the inner wall of tank
1.
[0014] Four is an optimum number for the channels 2, because this enables said channels
2 to cover all the axes. However, another number of channels 2 could be used, such
as three. Introducing unnecessary channels 2 into the tank 1 would unnecessarily increase
the weight, which is always an important consideration for spacecraft applications.
[0015] The propellant retention system includes a liquid/bubble trap assembly 9 situated
at the junction of the four channels 2 and the propellant outlet 8. The liquid/bubble
trap assembly 9 is constructed using perforated sheet metal having preferably equilateral
triangular holes, as will be more fully described below.
[0016] In operation, the V-channels 2 acquire and convey liquid propellant to the liquid/bubble
trap assembly 9 during zero-g and low-g phases of the spacecraft's mission. The liquid/bubble
trap assembly 9 also functions as a retention device to maintain the position of the
liquid propellant in the region of outlet 8 when operating under said zero-g and low-g
conditions. The system also prevents propellant from moving away from outlet 8 during
adverse acceleration conditions, thereby providing a continuous supply of gas-free
propellant.
[0017] The V-shaped channels 2 are easier to fabricate and less expensive than the complicated,
screened rectangular galleries of the prior art, and exhibit better propellant acquisition.
For a given cross-sectional area, V-shaped channels 2 provide a 10-15% increase in
liquid pumping capability over screened rectangular channels. The instant PMS provides
a reduction in propellant residuals compared with rectangular gallery PMS's. Screens
are eliminated from upper portions 11 of channels 2; consequently, serious problems
encountered in the screened gallery systems of the prior art, such as gas trapped
inside the galleries, propellant evaporation off the screens, etc., are minimized.
[0018] Channels 2 provide better propellant retention capability compared to the vane PMS's
of the prior art.
[0019] The interior of tank 1 that is occupied by gas and not by liquid propellant is termed
the "ullage". The pressurant gas is typically helium, pressurized to about 230 psi.
During an apogee motor burn in the illustrated satellite application, an external
pressurant tank and pressure regulator are used to maintain constant pressure in tank
1 during the apogee burn. After apogee burn, no new pressurant gas is introduced into
tank 1.
[0020] The spacecraft typically has two tanks 1A, 1B that are virtually identical. Tank
1A is for the liquid fuel, which may be mono-methylhydrazine (MMH). Tank 1B is for
the liquid oxidizer, which may be nitrogen tetroxide. (Tank 1 depicted in Fig. 1 is
for either fuel or oxidizer.) In the illustrated satellite embodiment, fuel tank 1A
is situated above the principal axis of the satellite. The principal axis passes through
oxidizer tank 1B, which is situated just below fuel tank 1A (Figs. 7 and 9). The principal
axis is sometimes known as the flat spin axis or the stable axis.
[0021] The tank 1 hemispheres 3, 5 are welded together by means of attachment ring 4. The
channels 2 are mechanically coupled to upper hemisphere 3 by means of a channel retainer
6 centered therein.
[0022] The type of passive propellant management system illustrated herein is not needed
for a spin stabilized spacecraft because centrifugal force can be used to expel the
liquid propellant from the tanks. Therefore, the specific application illustrated
in this specification is a three-axis stabilized geosynchronous satellite. Even with
such a satellite, however, the satellite is often made to spin, e.g., just prior to
firing of its perigee motor, for purposes of imparting angular momentum stiffness
to the satellite. For such an application, tank 1 is arranged within the satellite
so that the spinup axis of the satellite passes through channel retainer 6 and liquid/bubble
trap assembly 9 as illustrated in Fig. 1. Large motor accelerations, e.g., caused
by firing of the perigee or apogee motor, have a direction as illustrated; during
such a maneuver, liquid propellant is forced to the lower regions of tank 1. The illustrated
adverse acceleration (see Figs. 1 and 11) is that associated with a west stationkeeping
maneuver. The north, south, east, and west faces of tank 1 for the illustrated satellite
application are also shown in Fig. 1.
[0023] Liquid propellant is filled into tank 1 via propellant inlet/outlet 8, so that gas
will not be trapped in the vicinity of liquid/bubble trap assembly 9. Tank 1 is typically
filled between 75% and 92% with liquid propellant.
[0024] Fig. 1 illustrates a preferred embodiment in which channels 2B and 2D consist solely
of relatively open channel portions 11. On the other hand, channels 2A and 2C comprise
relatively open portions 11 as well as relatively closed portions 10, which are schematically
illustrated in Figs. 1 and 2 by dots. Said relatively closed portions 10 occupy those
regions of channels 2A and 2C within lower hemisphere 5, plus small contiguous regions
of channels 2A, 2C within upper hemisphere 3. The function of relatively closed portions
10 is to maintain continuous liquid flow during north-south stationkeeping maneuvers,
flat spin, and spinup procedures.
[0025] As illustrated in Figs. 3 and 4, there is a small gap (.25" towards the top ends
of closed portions 10 tapering down to about .1" towards the bottom ends of closed
portions 10 for the exemplary satellite) between the open end of the V of each V-channel
2 and the inside wall of tank 1. These gaps may be maintained by mechanical spacers
interspersed along each channel 2. For each relatively closed channel portion 10,
as depicted in Fig. 4, this gap forms a refillable liquid reservoir 12, as surface
tension tends to keep liquid therein. The gap size of reservoir 12 is based on the
magnitude of adverse acceleration expected during the mission. The higher the adverse
acceleration, the smaller the gap must be. If the gap is very small, it becomes mechanically
difficult to fabricate. For the exemplary satellite, the adverse acceleration is .0009
g. Reservoirs 12 have a much better propellant retention capability than those associated
with the prior art vane liquid communicators.
[0026] Figs. 3 and 4 show that each V-channel 2 is made by joining two elongated metal plates
13, forming an angle of 60° in the illustrated embodiment. Thus, the liquid path is
substantially in the shape of an equilateral triangle. For the exemplary satellite,
the opening between the open end of plates 13 is 1", i.e., the equilateral triangles
have legs that are an inch long.
[0027] Alternative to the use of the equilateral triangular shape, plates 13 can be made
to have an angle of less than 60°, and the resulting liquid communication path has
an isosceles triangular cross-section. For the same cross-sectional area, the isosceles
triangle moves the liquid faster than the equilateral triangle, because its perimeter
is bigger. However, such a channel 2 is heavier than the equilateral triangular channel
2.
[0028] Fig. 4 shows one technique by which the relatively closed portion 10 may be made:
a thin metal foraminous (perforated) plate 14 is placed over the open portion of the
V. The holes in plate 14 are numerous and small (on the order of .0015 inch diameter).
The desired hole size depends upon spin-generated acceleration and propellant load.
The shape of a hole is chosen so that the hole has as small a hydraulic radius as
possible for a given cross-sectional area. This maximizes the retentive power of plate
14. An equilateral triangular hole has a smaller hydraulic radius than a circular
or rectangular hole of the same cross-sectional area, but a greater hydraulic radius
than an isosceles triangular hole. However, an equilateral triangular hole is easier
to fabricate than an isosceles triangular hole. Therefore, equilateral triangular
holes are used for the exemplary satellite. The perforated plates 14 are formed simply
and inexpensively from materials such as titanium or steel by photoetching or laser
drilling.
[0029] Alternative to the use of a foraminous plate 14, a screen or mesh could cover the
openings of the V-channels 2 to create the relatively closed portions 10.
[0030] Fig. 5 illustrates details of liquid/bubble trap assembly 9. The liquid paths formed
by V-channels 2 pass into cylindrical portion 29 of assembly 9 via foraminous band
22, which forms the bottom annular portion of cylinder 29. Cylinder 29 is bounded
on the bottom by hemisphere 5 and on the top by plate 17. Plate 17 is closed, to counteract
liquid loss during maneuvers entailing adverse acceleration, and also to provide structural
stiffness.
[0031] The interior of cylinder 29 comprises liquid trap 27 plus bubble trap 28, both of
which are non-refillable.
[0032] Bulk space liquid trap 27 comprises the space within foraminous frustoconical upstream
gas arrestor 19, foraminous cylindrical communication tube 20, and an upper disk portion.
The upper disk portion of liquid trap 27 is that space formed between top plate 17,
foraminous vane-top plate 26, and a wholly foraminous portion of annular gas venting
window 16. Liquid trap 27 is a non-refillable closed trap. It retains propellant at
outlet 8 during spin-mode operation, and provides propellant for stable spin recovery.
A flat spin (spin about the principal axis) may be commanded for the exemplary satellite
during periods of emergency. During such an emergency maneuver, the upper disk portion
of liquid trap 27 desirably stores propellant. Cylinder 20 is made thin so that bubble
trap 28 can be situated between upper and lower portions of the liquid trap 27. Upstream
gas arrestor 19 is made narrow at the top so it can communicate with tube 20, and
wide at its bottom to complete an uninterrupted liquid flow path at the bottom of
tank 1 all the way from channels 2 to outlet port 8.
[0033] Metallic liquid communication vanes 21 provide mechanical support to assembly 9,
as well as a liquid communication path among the various components of liquid trap
27. The upper circular-cross-section end 23 of cylindrical communication tube 20 is
open.
[0034] The purpose of gas venting window 16 is to squeeze out gas when tank 1 is filled
with liquid initially. Foraminous portions of window 16 extend down cylinder 29 a
bit below vane-top plate 26. This extended lower region of window 16 covers some but
not all of the circumference of cylinder 29.
[0035] Bulk space bubble trap 28 is bounded by cylinder 29, plate 26, cylindrical communication
tube 20, and upstream gas arrester 19. Bubble trap 28 is not refillable.
[0036] Arrester 19, whose open end surrounds downstream gas arrester 18, acts as a backup
bubble trap. Cylindrical foraminous downstream gas arrester 18 surrounds outlet 8,
and acts as a bubble trap of last resort. The lower circular-cross-section end of
arrestor 18 is open and communicates with outlet 8. The holes in arresters 18 and
19 increase the area available to act as a barrier to gas entry. The upper plate 25
of downstream gas arrester 18 and the upper plate 24 of upstream gas arrester 19 are
closed for purposes of counteracting undesired liquid flow during maneuvers entailing
adverse acceleration.
[0037] External refillable trap 15 is a raminous accordion-like structure formed around
band 22 at the intersection of channels 2. Trap 15 is used primarily during the west
stationkeeping maneuver, and is optional, since reservoirs 12 may be sufficient for
this maneuver. Refillable trap 15 feeds propellant to nonrefillable liquid trap 27;
retains sufficient propellant under adverse accelerations to satisfy maneuver requirements;
and refills under conditions of zero g.
[0038] As stated previously, items 15, 16, 18, 19, 20, 22, and 26 are foraminous. They have
preferably three different hole sizes. Their holes have shapes such as to minimize
the hydraulic radius for a given cross-section, and thereby maximize retention capability.
As a practical matter, the holes are equilateral triangular in shape. This provides
more liquid retention capability than with circular or rectangular holes, although
less than for the harder-to-fabricate isosceles triangular holes. For the exemplary
satellite, the largest holes (about .06" diameter if they were circles) are in refillable
trap 15. The second largest holes (about .004" diameter if they were circles), are
in band 22. Items 16, 18, 19, 20, and 26 have holes that would be about .002" in diameter
if they were circles; these holes are relatively small so liquid will be retained
within cylinder 29 during spinup maneuvers (see Fig. 6).
[0039] The instant propellant management system has been designed so that each tank 1 may
experience lateral accelerations without adverse consequences. Lateral accelerations
occur when the exemplary satellite is launched by the U.S. space transportation system
(space shuttle). In that case, a lateral acceleration of about 4.6 g acts on tank
1. The lateral acceleration vector has a direction from the center of tank 1 through
channel 2D. Because of this, channel 2D is designed to comprise solely a relatively
open portion 11 throughout its length, for the same reason that the upper regions
of all channels 2 comprise relatively open portions 11 on account of the perigee maneuver:
the lateral acceleration of 4.6 g places the ullage about the entire length of channel
2D (but not about any other channel 2, because none of the propellant has been expended
at this point in the mission). This ullage would be sufficient to cause gas breakdown
within channel 2D even if it were relatively closed. This gas would be trapped in
channel 2D. So fabricating channel 2D of just a relatively open portion 11 avoids
this problem, and furthermore, advantageously saves weight.
[0040] In the illustrated embodiment, channel 2B also consists exclusively of a relatively
open portion 11, thus saving additional weight. This is possible because the relatively
closed portions 10 of channels 2A and 2C are adequate for providing the requisite
liquid pumping capability.
[0041] Figs. 6-11 illustrate the functioning of the instant propellant management system
during several different maneuvers of the exemplary satellite. In Figs. 6-11, liquid
propellant is represented by cross-hatchings; liquid flow is denoted by arrows; and
the relative size of liquid/bubble trap assembly 9 has been exaggerated for clarity.
[0042] Fig. 6 pertains to spinup and nutation control. The satellite spins up to about 36
RPM around its spinup axis for about 20 minutes. 211 cubic inches of propellant is
consumed from each of the two tanks 1. The maximum acceleration generated is 0.32
g. The faster the spin rate and the less propellant within the tank 1, the greater
the need for liquid retention capability. The relatively closed portions 10 of channels
2A and 2C provide enough retention capability that gas breakdown does not occur across
the gas/liquid interface in lower hemisphere 5. Liquid does not leave cylinder 29
of assembly 9 because the holes therein are sufficiently small.
[0043] After spinup, the satellite experiences a perigee motor burn. The liquid propellant
is forced towards lower hemisphere 5. Because of this phenomenon, the instant propellant
management system is designed so that the upper regions of all V-channels 2 comprise
relatively open portions 11. This is because during the perigee motor burn, the acceleration
is so great that even if the upper regions of the channels 2 were relatively closed,
gas would be injected into said channels 2 anyway. The gas would be trapped, and would
be very difficult to remove later. With the use of relatively open portions 11, the
liquid flows back into and along channels 2 in these upper regions anyway, by capillarity.
Furthermore, eliminating screening or perforated plates 14 in these upper regions
of channels 2 advantageously saves weight.
[0044] After perigee motor burn, the satellite transitions to a stable spin of about 15
RPM around its principal axis (which passes through the satellite's center of mass),
and the perigee motor separates from the satellite. During this maneuver, no flow
is required from the propellant tanks 1. This maneuver is illustrated in Fig. 7, in
which tank 1A is the fuel tank and tank 1B is the oxidizer tank. This maneuver is
not a problem for the oxidizer tank 1B, because the ullage is in the upper hemisphere
3 of said tank 1B. However, this maneuver places a great deal of strain on the retention
capability of the channels 2 within the fuel tank 1A, because the ullage is in the
lower hemisphere 5 of tank 1A. Because of this great need for retention capabililty,
the lower regions of at least two of the channels, in this case 2A and 2C, comprise
relatively closed portions 10.
[0045] After the perigee motor separates, the center of mass, and hence the principal axis,
moves upwards, but it still lies within oxidizer tank 1B.
[0046] After the satellite undergoes flat spin, it despins to a three-axis stabilized mode.
At this time, each tank 1 is more than 50% full. The geometry of the liquid within
tanks 1 is the same as that illustrated in Fig. 7. Within the fuel tank 1A, channels
2 provide direct communication to the bulk propellant at the top of the tank 1A for
continuing the supply of propellant to outlet port 8.
[0047] Figure 8 illustrates the movement of liquid propellant just after apogee motor burn.
The propellant is settled over outlet 8 by axial acceleration along the spinup axis.
As the burn progresses, the top regions of the channels 2 are no longer submerged
in propellant. The relatively closed portions 10 of the channels 2 must prevent gas
from entering the system. About 85% of the total supply of propellant is consumed
during the apogee burn.
[0048] Fig. 9 illustrates the despin of the satellite to a three-axis stabilized mode after
apogee burn. At this point, each tank 1 is less than 50% full. The fuel within tank
1A is initially provided from external refillable trap 15 and upstream gas arrester
19. As this gets depleted, the fuel is eventually supplied from the upper disk portion
of liquid trap 27. Gas enters bubble trap 28. Within oxidizer tank 1B, oxidizer is
supplied from liquid trap 27 and is displaced by the inflow of the bulk propellant.
[0049] Fig. 10 illustrates a north stationkeeping maneuver of the satellite after it is
in geosynchronous orbit. (A south stationkeeping maneuver would be identical except
reversed.) For this maneuver, there is a small (about 0.005 g) lateral acceleration,
which passes from the center of the tank 1 through channel 2A. In Fig. 10, it is seen
that channel 2C is experiencing a puddling of liquid extending just above the midline
of the tank 1. It is for this reason that the relatively closed portions 10 of channels
2A and 2C are made to extend a bit above the midline of the tank 1; this enables the
liquid that puddles above the midline during north-south stationkeeping maneuvers
to be retained within the system for subsequent use during the mission. During these
maneuvers, propellant withdrawn from liquid trap 27 is displaced by inflow from channels
2A and 2C. Propellant retained in one quadrant of refillable trap 15 (in the case
of north stationkeeping, the leftmost quadrant) can also be added to the supply of
required flow. As the satellite reverts to a zero g condition after completion of
the maneuver, liquid propellant refills channels 2, reservoirs 12, and external trap
15. The refill time of reservoir 12 and external trap 15 is typically less than 25
minutes.
[0050] Finally, Fig. 11 illustrates the west stationkeeping maneuver, which places on the
satellite an adverse acceleration in the direction illustrated. Capillary feed from
refillable trap 15 and reservoirs 12 provides the required flow. The isolated liquid
in the upper hemisphere 3 is later captured by the channels 2.
[0051] The above description is included to illustrate the operation of the preferred embodiments
and is not meant to limit the scope of the invention. The scope of the invention is
to be limited only by the following claims. From the above discussion, many variations
will be apparent to one skilled in the art that would yet be encompassed by the spirit
and scope of the invention.